Methods And Systems For Making An Optical Functional Film

ABSTRACT

A method to make dyed functional film comprising the steps of providing a soluble polymer material; adding an appropriate solvent to the polymer material to make a soluble polymer solution; providing a soluble dye; adding an appropriate solvent to the dye to make a soluble dye solution; adding the dye solution to the polymer or PVA solution, and introducing the dyed polymer or PVA solution to a solution casting device; removing a thin dyed functional film from the casting device; and letting the dyed functional film dry and solidified.

INCORPORATION BY REFERENCE

This application claims the benefit of priority under 35 U.S.C. 119(e)to the filing date of U.S. provisional patent application No. 62/116,545“Solution Casting Method” which was filed on Feb. 15, 2015, and whichare incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to an optical component, andmore particularly it is directed to methods and system of makingfunctional plastic film, functional Polymer film, or functional PVAfilm.

BACKGROUND OF THE INVENTION

It is well known that Ultraviolet (UV) light can cause serious flashburns to the cornea from high intensity light sources. Thus our eyesneed protection from these harmful UV lights. The situations where oureyes definitely need protection from UV lights are welding, exposing tosunlight at elevation above 5000 ft (1524 m), or when the sun glares offsnow or water, tanning, etc.

Not just UV light, infrared is also harmful. Wireless communication,appliances, computer, and lights all emit different levels of harmfulradiation. In fact, there are also plenty of natural infrared, such asthose from sunlight. Sunlight is composed of thermal-spectrum radiationthat is slightly more than half infrared. At zenith, sunlight providesan irradiance of approximately 1 kilowatt per square meter at sea level,of which 527 watts is infrared radiation. Once the sunlight reaches thesurface of Earth, almost all thermal radiation are of infrared.

The energy of sunlight on the ground can be categorized intoapproximately 3% Ultraviolet (UV) rays, 44% visible rays, and 53%Infrared (IR) rays. Therefore, when exposed to intense sunlight for alengthy period of time without protection, human eyes may experience aburning or stinging sensation that is often accompanied by fatigue. Suchdiscomfort can be especially noticeable for those wearing contactlenses, as the infrared can be absorbed by the contact lenses causingthem to “warm up”. Eye doctors always encourage a habit of putting onsunglasses when staying out in the sun for a period.

Traditionally, for protection lens to block harmful rays from a lightsource, the lenses must be coated with one or more layers of IR and/orvisible dyes. Usually, soluble dyes and/or metallic oxide pigments areused for coating to absorb or reflect light of certain frequencies, eg.,IR frequencies, UV frequencies, etc. Thus, coated lens would reduce ormitigate eye diseases such as cataract and glaucoma.

Because of the importance of sunglasses and protecting eyewear, therehave been many coating techniques invented. IR or visible coating can beapplied by dipping or spraying a solvent IR or visible dyes on anotheroptical layer of a lens. However, because the majority of lenses arecurved, the curvature of the lenses presents a significant obstacle inthe application of the IR or visible coating, as the application of thecoating may be uneven. As a consequence, the uneven application of thecoating on a curved surface would reduce the effectiveness of theprotection layers.

Using traditional methods like extrusion or injection, IR or visibledyes are added during the processes. Extrusion is a process used tocreate objects of a fixed cross-sectional profile. A material is pushedor pulled through a die of the desired cross-section. In a plasticextruding process, plastic is first melted into a viscous, semi-liquidstate. After it softens, the plastic is pressed through a contouredopening. Using this technique, a curved lens may be created by pushing asoftened optical film through a contoured opening.

Injection molding is a manufacturing process for producing parts byinjecting material into a mold. Material for the part is fed into aheated barrel, mixed, and forced into a mold cavity, where it cools andhardens to the configuration of the cavity. For optical plastic films,whether it is an extrusion or injection method, heat is needed to softenthe plastic films so they can be shaped curvaceously. Since dyes aresensitive to heat, some dye degradation occurs, and the effectiveness ofeye protection reduces.

Another problem with these IR or visible coated lens is that they areeasily scratched and are not resistant to chemicals or elements. Overtime the protection layers lose their effectiveness and become harmfulif not detected and replaced. To overcome this problem lensmanufacturers have put another protection layer on top of the IR/visiblelayer either by spraying, dipping, or injection. However, as aconsequence, additional layers make the lens thicker and to have aminimum thickness, which is a barrier for eyewear design and comfort.

Furthermore, traditional coating methods by injection or extrusionmethods are aesthetically less appealing because infrared dye appearsgreen in such a coating. In order to counteract or offset theundesirable green color, gray colors may be added to the PVA film. Theaddition of such gray colors, however, reduces the penetration of light,and therefore the visibility for the viewers, significantly. Finally,the addition of the gray colors to the PVA films on the lens results inhigher costs for the lenses, and thus higher costs for the end products.Therefore, material and manufacturing processes for IR absorbing lensesthat are inexpensive and quick are desirable.

Recently, to overcome the drawbacks of extrusion and injection methods,solution casting method has been invented and preferred. Thismanufacturing technology is unique in that the process does not requireconventional extrusion or injection molding technologies, yet it readilyincorporates components and features traditionally produced by theseprocesses. This method utilizes a mandrel, or inner diameter mold, thatis immersed in a tank of polymer solution or liquid plastic that hasbeen specifically engineered for the process. Due to a combination ofthermal and frictional properties, the polymer solution then forms athin film around the mold. The mold is then extracted from the tank in aprecisely controlled manner, followed by a curing or drying process.

Other casting devices being used in a solution casting method are a beltor drum machines. Typically, supporting belts are 1.0 to 2.0 m wide and10 to 100 m long. Stainless steel belts are between 1.0 and 2.0 mmthick. Drums are typically 4 to 8 m in diameter and 1.20 to 1.50 m wide.The belt channel allows a stream of air to flow in machine direction orcounter direction. The drum is tightly sealed to prevent vapor emissionsand to direct the air stream against the direction of drum movement. Oneof the two pulleys or drums is connected to a drive that requiresextremely accurate speed control to avoid even slight speed variations.One drum is connected to a servo system that adjusts belt tension inorder to ensure constant flatness and “absence” of belt movements(vibrations) in the critical area just behind the caster, and to controlthe expansion and dilatation of the belt length caused by temperaturechanges. Belt machines have a guide system to avoid belt shifting duringoperation. The belt is guided by horizontal movements of the supportdrums. Many different support materials have been used for belts:Copper, silver-plated copper, chromium-plated steel, stainless steel,metal coated with polyvinylalcohol or gelatin, polyester film, PTFE filmand other polymer films. At present the commonest support materials arestainless steel and chromium-plated surfaces. Important items for beltand drum machines are the material's heat conductivity, the technicalprocesses used to create the required surface finish and the options forrepairing small surface defects. This cast technique permits simpleproduction of films with structured surfaces. The belt surface isclearly and accurately replicated on one surface of the film. Thetechniques used to adapt the surface of the drums or belts to highlyglossy, structured or matt film finishes are proprietary methods.

Once the first layer of thin film is appropriately solidified, secondaryfeatures can be added to the product such as braided or coiled wire,laser-cut hypotubes or engineered metal reinforcements to preventkinking, or imaging targets specific to the intended medicalapplication. Multiple casting steps can then be repeated to encapsulatethe reinforcements, build up wall thickness, add additional lumens andoptimize column strength. The part is then removed from the mold afterit is cured or solidified. This method works with liquid forms ofsolvent polymers without using excessive heat to cure the part. Sincethis method uses centrifugal force to shape the part, with the rightliquidity ratio, a very thin layer of IR or visible dye solution can beadded to an optical film without using excessive heat.

Another method to make the film is a static method such as cavity moldor plate casting or other similar method.

OBJECT OF THE INVENTION

Accordingly, it is the object of this invention to provide a method andsystem for manufacturing functional films.

It is also the object of the present invention to make optical filmsthat have maximum optical purity and extremely low haze, using readilyincorporated mixture components.

It is also the object of the present invention to make virtuallyisotropic functional films that have excellent flatness and dimensionalstability.

It is also the object of the present invention to make functional filmswith absorbing dye soluble and offers more precision.

It is also the object of the present invention to make functional filmswithout damaging or degrading heat-sensitive dyes.

It is also the object of the present invention to makedyed functionalfilms without an additional liquid coated layer, thus no protectionlayer is exposed to scratches or chemicals or elements.

It is also the object of the present invention to manufacture functionalfilms that have less treatment, less layers, less defect, and lessdelamination, and save process time.

It is also the object of the present invention to manufacture functionalfilms that are easily processed, have better quality and good function.

SUMMARY OF INVENTION

A method to make a dyed functional film comprising the steps of:providing a soluble polymer material, PVA powder, or PVA material;adding a solvent or water to the polymer material, PVA powder, or PVAmaterial to make a soluble polymer or PVA solution; providing a solubledye; adding a solvent to the IR and/or laser dye, photochromic, visibledye to make a soluble dye solution; adding the dye solution to thepolymer or PVA solution; introducing the dyed polymer or PVA solution toa solution casting device; letting the solution casting device make athindyed functional film from the dyed polymer or PVA solution; removingthe thin dyed functional film from the casting device; letting the filmdry and solidified;

In one embodiment, the dyed functional film is dried in a temperaturebetween 40-100° C. In another embodiment, the dyed functional filmthickness is between 0.0025 mm-2.0 mm.

In one aspect of the invention, a method to manufacture a functionalfilm is disclosed which comprises the steps of: providing a solublepolymer or a PVA material; adding a polymer solvent to the polymer orthe PVA material to make a soluble polymer solution or a PVA solution;providing a soluble dye; adding a dye solvent to the soluble dye to makea soluble dye solution; adding the dye solution to the polymer solutionor the PVA solution thereby making a dyed polymer solution or a dyed PVAsolution; introducing the dyed polymer solution or the dyed PVA solutionto a solution casting device; allowing the solution casting device tomake a thin dyed optical film from the dyed polymer solution or the dyedPVA solution; removing the thin dyed optical film from the device;allowing the thin dyed optical film to dry and to solidify. In oneembodiment, the dyed optical film is dried in a temperature between40-100° C. In one embodiment, the dyed optical film thickness is between0.0025 mm-2.0 mm. In one embodiment, the polymer is selected from agroup consisting of TAC, Cellulose acetate, Cellulose propionate,Polyurethane, PVC, Silicon urethane copolymer, Acrylic, COP,Tetrafluoroethylene polymer, PC, PP, PE, Polyethersulfon,Polyetherimide, Polyvinylidene fluoride, etc., is added to anappropriate solvent, such as, triphenyl phosphate, diphenyl phosphate,dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone,butanol, butyl acetate, butanol, Biphenyl diphenyl phosphate,Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC,CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride. In one embodiment,the polymer solvent is selected from a groupconsisting of triphenyl phosphate, diphenyl phosphate, dichloromethane,methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butylacetate, butanol, Biphenyl diphenyl phosphate, Trichloromethane, MEK,EAC, IPA, MIBK, BCS, MCS, EAC, BAC, CYCLOHEXANONE, Tetrahydrofuran,Ether, Esters, Polyimides, Dimethylformamide, Polyvinylalcohol, MethylCellulose, Starch derivatives, Gelatine, Methyl-ethylketon,Tetrahydrofuran, Methylene Chloride, water. In one embodiment, the thindyed optical film is capable to function as an eyewear lens, a vehiclewindow, a camera lens, a microscope lens, a building window, anelectronic screen or a lamp cover protection. In one embodiment, thethin dyed optical film is laminated to a glass lens or a plastic lens.In one embodiment, a vacuum coating is applied to the thin dyed opticalfilm. In one embodiment, an anti-Reflective coating is applied to thethin dyed optical film. In one embodiment, a hard coating is applied tothe thin dyed optical film. In one embodiment, a water resistant coatingis applied to the thin dyed optical film. In one embodiment, a scratchresistant coating is applied to the thin dyed optical film. In oneembodiment, the thin dyed optical film is stretched to become a PVApolarized film. In one embodiment, the soluble dye is selected from agroup consisting of an IR dye, a visible dye, a photochromic dye, or anabsorbing dye. In one embodiment, the IR dye is selected from a groupconsisting of Tetrakis ammonium structure, Iminium phthalocyanines,naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadraticacid derivatives, immonium dyes, perylenes Dianthrones CyaninesHeteroaromatics Metal Dithiolenes Oxadiazoles Phthalocyanines SpiropyraTetraaryldiamines Triarylamines, Water soluble phthalocyanine and/ornaphthalocyanine dye chromophores or similar dye.

In another aspect of the invention, a method to manufacture a functionalfilm is disclosed which is comprising the steps of: providing a solublepolymer; adding a polymer solvent to the a soluble polymer to make asoluble polymer solution; providing a soluble dye; adding a portion ofPVA material to the soluble polymer solution; adding a dye solvent tothe soluble dye to make a soluble dye solution; adding the dye solutionto the polymer solution thereby making a dyed polymer solution;introducing the dyed polymer solution to a solution casting device;allowing the solution casting device to make a thin dyed optical filmfrom the dyed polymer solution; removing the thin dyed optical film fromthe device; allowing the thin dyed optical film to dry and to solidify.

In another aspect of the invention, an eyewear lens comprising a thindyed optical film is disclosed wherein the thin dyed optical film ismade with a portion of dyed polymer solution in a solution castingdevice wherein the dyed polymer solution is comprised of a portion ofsoluble dye solution and a portion of soluble polymer solution whereinthe soluble dye solution is comprised of a portion of soluble dye and aportion of dye solvent and wherein the soluble polymer solution iscomprised of a portion of polymer solvent and a portion of solublepolymer.

In another aspect of the invention, an eyewear lens comprising a thindyed optical film wherein the thin dyed optical film is made with aportion of dyed PVA solution in a solution casting device wherein thedyed PVA solution is comprised of a portion of soluble dye solution anda portion of soluble PVA solution wherein the soluble dye solution iscomprised of a portion of soluble dye and a portion of dye solvent andwherein the soluble PVA solution is comprised of a portion of polymersolvent and a portion of PVA material. In one embodiment, the solublepolymer is selected from a group consisting of TAC, Cellulose acetate,Cellulose propionate, Polyurethane, PVC, Silicon urethane copolymer,Acrylic, COP, Tetrafluoroethylene polymer, PC, PP, PE, Polyethersulfon,Polyetherimide, Polyvinylidene fluoride, etc., is added to anappropriate solvent, such as, triphenyl phosphate, diphenyl phosphate,dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone,butanol, butyl acetate, butanol, Biphenyl diphenyl phosphate,Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC,CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride. In embodiment, the polymer solvent is selected from a groupconsisting of triphenyl phosphate, diphenyl phosphate, dichloromethane,methanol, resorcinol, tetraphenyl diphosphate, acetone, butanol, butylacetate, butanol, Biphenyl diphenyl phosphate, Trichloromethane, MEK,EAC, IPA, MIBK, BCS, MCS, EAC, BAC, CYCLOHEXANONE, Tetrahydrofuran,Ether, Esters, Polyimides, Dimethylformamide, Polyvinylalcohol, MethylCellulose, Starch derivatives, Gelatine, Methyl-ethylketon,Tetrahydrofuran, Methylene Chloride, water. In one embodiment, solubledye is selected from a group consisting of an IR dye, a visible dye, aphotochromic dye, or an absorbing dye. In one embodiment, the IR dye isselected from a group consisting of Tetrakis ammonium structure, Iminiumphthalocyanines, naphthalocyanines, metal complexes, azo dyes,anthraquinones, quadratic acid derivatives, immonium dyes, perylenesDianthrones Cyanines Heteroaromatics Metal Dithiolenes OxadiazolesPhthalocyanines Spiropyra Tetraaryldiamines Triarylamines, Water solublephthalocyanine and/or naphthalocyanine dye chromophores. In oneembodiment, the polymer solvent is selected from a group consisting oftriphenyl phosphate, diphenyl phosphate, dichloromethane, methanol,resorcinol, tetraphenyl diphosphate, acetone, butanol, butyl acetate,butanol, Biphenyl diphenyl phosphate, Trichloromethane, MEK, EAC, IPA,MIBK, BCS, MCS, EAC, BAC, CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters,Polyimides, Dimethylformamide, Polyvinylalcohol, Methyl Cellulose,Starch derivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran,Methylene Chloride, water. In one embodiment, soluble dye is selectedfrom a group consisting of an IR dye, a visible dye, a photochromic dye,or an absorbing dye. In one embodiment, the IR dye is selected from agroup consisting of Tetrakis ammonium structure, Iminiumphthalocyanines, naphthalocyanines, metal complexes, azo dyes,anthraquinones, quadratic acid derivatives, immonium dyes, perylenesDianthrones Cyanines Heteroaromatics Metal Dithiolenes OxadiazolesPhthalocyanines Spiropyra Tetraaryldiamines Triarylamines, Water solublephthalocyanine and/or naphthalocyanine dye chromophores.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the invention will not bedescribed with reference to the drawings of certain preferredembodiments, which are intended to illustrate and not to limit theinvention, and in which

FIG. 1 is an illustrative view of the preparation of a polymer or PVAsolution in a preferred solvent or water.

FIG. 2 is an illustrative view of the preparation of an IR dye and/orlaser dye, photochromic, visible dye solution in a preferred solvent orwater.

FIG. 3 is an illustrative view of a typical solution casting method andapparatus.

FIG. 4 is an illustrative view of the process of making a functionalfilm using Solution Casting Method.

FIG. 5 is an illustrative view of laminating a new functional film as anoptical component with other materials to make an eyewear optical lens,camera lens, microscope lens, car windows, building windows, electronicscreen, lamp cover protection, etc.

DETAILED DESCRIPTION OF THE INVENTION

Some embodiments are described in detail with reference to the relateddrawings. Additional embodiments, features, and/or advantages willbecome apparent from the ensuing description or may be learned bypracticing the invention. The following description is not to be takenin a limiting sense, but is made merely for the purpose of describingthe general principles of the invention. The steps described herein forperforming methods form one embodiment of the invention, and, unlessotherwise indicated, not all of the steps must necessarily be performedto practice the invention, nor must the steps necessarily be performedin the order listed.. It should be noted that references to “an” or“one” or “some” embodiment(s) in this disclosure are not necessarily tothe same embodiment, and such references mean at least one.

In accordance with the practice of the present invention, the methodsand system of making a functional film disclosed herein provides manyimportant advantages over those of prior arts. Specifically, the currentinvention yields a virtually isotropic, flat, and dimensionally stablefunctional film. Furthermore, the functional film achieves maximumoptical purity and extremely low haze. The film is also dyed to aprecise specification without affected by dye degradation problem. As aresult, the present functional film has less treatment, less defect,less delamination, and less stress, and, thus, the optical lens requiresfewer layers, and process time is shorter. Although yielding manyadvantages, the current method uses readily incorporated mixturecomponents used in the traditional methods. The current invention doesnot increase material costs, and, in certain cases, it actually reducesmaterial costs because it yields accurate opticalproperties/specification, and thinness functional films, which in turnreduce the number of layers in an optical lens.

Referring to FIG. 1, a plastic polymer or PVA material 101, such as TAC,Cellulose acetate, Cellulose propionate, Polyurethane, PVC, Siliconurethane copolymer, Acrylic, COP, Tetrafluoroethylene polymer, PC, PP,PE, Polyethersulfon, Polyetherimide, Polyvinylidene fluoride, etc., isadded to an appropriate solvent 102, such as water, triphenyl phosphate,diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyldiphosphate, acetone, butanol, butyl acetate, butanol, Biphenyl diphenylphosphate, Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC,CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride, Polyvinyl Alcohol, etc., to make the first solution 100,liquid A, a plastic polymer or PVA solution.

Referring to FIG. 2, a solute 102 such as IR and/or visible dye,photochromic dye, or any absorbing dyes, is added to an appropriatesolvent 202 such as triphenyl phosphate, diphenyl phosphate,dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone,butanol, butyl acetate, butanol, Biphenyl diphenyl phosphate,Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC,CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride, water, etc., to make the second solution 200, liquid B, a dyesolution.

Referring to FIG. 3, the polymer casting method used in this inventionis depicted. Polymer material, PVA powder, or PVA material 301 is mixedwith a solvent 302. In one embodiment, low heat under 100° C. may beused to speed up the dissolving of the polymer in the solvent. However,in another embodiment, other polymer materials, such as TAC, may notneed any heat to dissolve. The solution may be further processed toarrive at the required solution for making a functional film withcertain optical properties. The final polymer or PVA solution is thenintroduced to the casting device 303 as depicted. In one embodiment, thefinal polymer or PVA solution is deposited onto a moving belt 304through a caster or spreader 305. The polymer or PVA solution is driedand solidified by a stream of air 306 flowing in a belt channel 307against the direction of the moving belt. It is appreciated that inother embodiments the stream of air 306 may flow in the direction of themoving belt. It is also appreciated that dry air, its direction, beltspeed, space of the belt channel, etc. are calibrated such that thefunctional film achieve a desired thickness, dryness, and otherqualities. Moreover, by the time the functional film reaches the filmtake-off 308 the input polymer or PVA solution must be solidified enoughto be taken off the belt for further drying or processing.

Referring to FIG. 4, the casting method as depicted in FIG. 3 is adaptedfor this invention. A liquid A, a polymer or PVA solution, is made byadding a polymer material 401 to an appropriate solvent 402. Liquid B, adye solution, is made adding a dye 403, which can be IR or visible dye,photochromic dye, or any absorbing dyes, to an appropriate solvent 404.In one embodiment, the Liquid B is comprised of between 0.05% to 5% ofIR or visible dye, or photochromic dye or absorbing dye and the restbeing in appropriate solvent. In one embodiment, the preferredembodiment is Liquid B comprising 3% of the dye. The resulting solutionsare mixed together to make dyed polymer solution 405. In one embodiment,water soluble PVA (polyvinyl alcohol) with IR dye may also contain fewpercent of solvent soluble polymer, less than 10% of solvent solublepolymer, in the mix. In one embodiment, the Liquid A is comprised ofapproximately. 9% to 25% of Polymer or PVA powder and 75% to 91% ofappropriate solvent.

The dyed polymer solution 405 is next introduced into a solution castingdevice 406. This device would utilize a large belt 407 whose materialand design are made appropriate for a desired functional film. In apreferred embodiment, the film is introduced to a dry environment wherethe temperature is between 40-100° C. The functional film iscontinuously taken off the moving belt for further drying, processing,rolled or sheeted. It is then used to produce an eyewear lens, cameralens, microscope lens, car windows, building windows, electronic screen,lamp cover protection, etc. In a preferred embodiment, the functionalfilm thickness is between 0.015 mm-3.0 mm. Different films withdifferent optical properties can be laminated together to obtain thedesired eyewear lens, camera lens, microscope lens, car windows,building windows, electronic screen, lamp cover protection, etc. In oneembodiment, referring to FIG. 5, a curved lens 503 is made whereinvisible and/or IR dyed optical film 501, which is made using the presentmethod as depicted in FIG. 3, is laminated on another clear film orglass 500, which has certain optical properties. Anotherscratch-resistant optical glass 502 is laminated on top of the dyedfunctional film 501 to protect the IR/visible layer from scratches,chemicals, and/or the elements.

1. A method to manufacture a functional film comprising the steps of:providing a soluble polymer or a PVA material; adding a polymer solventto said polymer or said PVA material to make a soluble polymer solutionor a PVA solution; providing a soluble dye; adding a dye solvent to saidsoluble dye to make a soluble dye solution; adding said dye solution tosaid polymer solution or said PVA solution thereby making a dyed polymersolution or a dyed PVA solution; introducing said dyed polymer solutionor said dyed PVA solution to a solution casting device; allowing saidsolution casting device to make a thin dyed optical film from said dyedpolymer solution or said dyed PVA solution; removing said thin dyedoptical film from said device; allowing said thin dyed optical film todry and to solidify.
 2. The method of claim 1, wherein said dyed opticalfilm is dried in a temperature between 40-1000 C.
 2. The method of claim1, wherein said dyed optical film thickness is between 0.015 mm-3.0 mm.3. The method of claim 1, wherein said polymer is selected from a groupconsisting of TAC, Cellulose acetate, Cellulose propionate,Polyurethane, PVC, Silicon urethane copolymer, Acrylic, COP,Tetrafluoroethylene polymer, PC, PP, PE, Polyethersulfon,Polyetherimide, Polyvinylidene fluoride, Polyox (Ethylene Oxide), etc.,is added to an appropriate solvent, such as, triphenyl phosphate,diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyldiphosphate, acetone, butanol, butyl acetate, butanol, Biphenyl diphenylphosphate, Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC,CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride, Alcohol, etc.
 4. The method of claim 1, wherein said polymersolvent is selected from a group consisting of triphenyl phosphate,diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyldiphosphate, acetone, butanol, butyl acetate, butanol, Biphenyl diphenylphosphate, Water, Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC,BAC, CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride, water, Alcohol, etc.
 5. The method of claim 1, wherein saidPVA solvent is selected from group consisting of Water and/or Alcohol.6. The method of claim 1, wherein said thin dyed optical film is capableto function as an eyewear lens, a vehicle window, a camera lens, amicroscope lens, a building window, an electronic screen, a lamp coverprotection, a phone screen, a TV screen, a computer screen or anappliance equipment.
 7. The method of claim 1, wherein said thin dyedoptical film is laminated to a glass lens or a plastic lens.
 8. Themethod of claim 1, wherein a vacuum coating is applied to said thin dyedoptical film.
 9. The method of claim 1, wherein an anti-Reflectivecoating is applied to said thin dyed optical film.
 10. The method ofclaim 1, wherein a hard coating is applied to said thin dyed opticalfilm.
 11. The method of claim 1, wherein a water resistant coating isapplied to said thin dyed optical film.
 12. The method of claim 1,wherein a scratch resistant coating is applied to said thin dyed opticalfilm.
 13. The method of claim 1, wherein said thin dyed optical film isstretched to become a PVA polarized film.
 14. The method of claim 1,wherein soluble dye is selected from a group consisting of an IR dye, avisible dye, a photochromic dye, or an absorbing dye.
 15. The method ofclaim 14, wherein said dye is selected from a group consisting ofTetrakis ammonium structure, Iminium phthalocyanines, naphthalocyanines,metal complexes, azo dyes, anthraquinones, quadratic acid derivatives,immonium dyes, perylenes Dianthrones Cyanines Heteroaromatics MetalDithiolenes Oxadiazoles Phthalocyanines Spiropyra TetraaryldiaminesTriarylamines, Water soluble phthalocyanine and/or naphthalocyanine dyechromophores.
 16. A method to manufacture a functional film comprisingthe steps of: a. providing a soluble polymer; b. adding a polymersolvent to said a soluble polymer to make a soluble polymer solution; c.providing a soluble dye; d. adding a portion of PVA material to saidwater soluble polymer solution; e. adding a dye solvent to said solubledye to make a soluble dye solution; f. adding said dye water solution tosaid polymer solution thereby making a dyed polymer solution; g.introducing said dyed polymer solution to a solution casting device; h.allowing said solution casting device to make a thin dyed optical filmfrom said dyed polymer solution; i. removing said thin dyed optical filmfrom said device; j. allowing said thin dyed optical film to dry and tosolidify.
 17. An eyewear lens comprising a thin dyed optical filmwherein said thin dyed optical film is made with a portion of dyedpolymer solution in a solution casting device wherein said dyed polymersolution is comprised of a portion of soluble dye solution and a portionof soluble polymer solution wherein said soluble dye solution iscomprised of a portion of soluble dye and a portion of dye solvent andwherein said soluble polymer solution is comprised of a portion ofpolymer solvent and a portion of soluble polymer.
 18. An eyewear lenscomprising a thin dyed optical film wherein said thin dyed optical filmis made with a portion of dyed PVA solution in a solution casting devicewherein said dyed PVA solution is comprised of a portion of soluble dyesolution and a portion of soluble PVA solution wherein said soluble dyesolution is comprised of a portion of soluble dye and a portion of dyesolvent and wherein said soluble PVA solution is comprised of a portionof polymer solvent and a portion of PVA material.
 19. The eyewear lensof claim 17, wherein said soluble polymer is selected from a groupconsisting of TAC, Cellulose acetate, Cellulose propionate,Polyurethane, PVC, Silicon urethane copolymer, Acrylic, COP,Tetrafluoroethylene polymer, PC, PP, PE, Polyethersulfon,Polyetherimide, Polyvinylidene fluoride, etc., is added to anappropriate solvent, such as, triphenyl phosphate, diphenyl phosphate,dichloromethane, methanol, resorcinol, tetraphenyl diphosphate, acetone,butanol, butyl acetate, butanol, Biphenyl diphenyl phosphate,Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC,CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride.
 20. The eyewear lens of claim 17, wherein said polymer solventis selected from a group consisting of triphenyl phosphate, diphenylphosphate, dichloromethane, methanol, resorcinol, tetraphenyldiphosphate, acetone, butanol, butyl acetate, butanol, Biphenyl diphenylphosphate, Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC,CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride, water, alcohol.
 21. The eyewear lens of claim 17, whereinsoluble dye is selected from a group consisting of an IR dye, aphotochromic dye, an absorbing dye, or visible dye.
 22. The eyewear lensof claim 21, wherein said IR dye is selected from a group consisting ofTetrakis ammonium structure, Iminium phthalocyanines, naphthalocyanines,metal complexes, azo dyes, anthraquinones, quadratic acid derivatives,immonium dyes, perylenes Dianthrones Cyanines Heteroaromatics MetalDithiolenes Oxadiazoles Phthalocyanines Spiropyra TetraaryldiaminesTriarylamines, Water soluble phthalocyanine and/or naphthalocyanine dyechromophores.
 23. The eyewear lens of claim 18, wherein said polymersolvent is selected from a group consisting of triphenyl phosphate,diphenyl phosphate, dichloromethane, methanol, resorcinol, tetraphenyldiphosphate, acetone, butanol, butyl acetate, butanol, Biphenyl diphenylphosphate, Trichloromethane, MEK, EAC, IPA, MIBK, BCS, MCS, EAC, BAC,CYCLOHEXANONE, Tetrahydrofuran, Ether, Esters, Polyimides,Dimethylformamide, Polyvinylalcohol, Methyl Cellulose, Starchderivatives, Gelatine, Methyl-ethylketon, Tetrahydrofuran, MethyleneChloride, water, or similar solvent.
 24. The eyewear lens of claim 18,wherein soluble dye is selected from a group consisting of an IR dye, aphotochromic dye, or an absorbing dye, or visible dye.
 25. The eyewearlens of claim 24, wherein said IR dye is selected from a groupconsisting of Tetrakis ammonium structure, Iminium phthalocyanines,naphthalocyanines, metal complexes, azo dyes, anthraquinones, quadraticacid derivatives, immonium dyes, perylenes Dianthrones CyaninesHeteroaromatics Metal Dithiolenes Oxadiazoles Phthalocyanines SpiropyraTetraaryldiamines Triarylamines, Water soluble phthalocyanine and/ornaphthalocyanine dye chromophores, or other similar dye.